1987 NISSAN PULSAR clutch

190
ELECTRICAL SYSTEM
CAUTION: To prevent severe electrical shock extreme care must be taken when
working on or near the electronic ignition system as dangerous high tension voltages
are produced in both the primary and secondary circuits. See the text fo\
r
precautionary notes.

SPECIFICATIONS
BATTERY
Type ..................................................12 volt lead acid
Polarity to earth .................................... Negative ( - )
Specific gravity:
Fully charged ................................... A bove 1.250
Fully discharged ................................Below 1.130
ALTERNATOR
Make .................................................Bosch or Hitachi
Maximum output .......................................... 70 amps
Polarity to earth .................................... Negative ( - )
Stator windings ......................................... Star wound
Regulator type ................................................ Integral
Brush length minimum:
Bosch ........................................................ 5.0 mm
Hitachi ............................. 6.0 mm or limit mark
STARTER MOTOR
Make .................................................Hitach i or Bosch
Type ............................ 4 pole 4 brush reduction gear
Operation control.................................. Solenoid and
overrunning clutch
Undercut of commutator (maximum):
Hitachi ...................................................... 0.8 mm
Brush length (minimum):
Bosch ........................................................ 8.0 mm
Hitachi ........................................................11 mm
Brush spring tension;
Hitachi ............................................... 15.7-19.6 N
Hitachi:
Drive pinion stopper clearance ........ 0.3-1.5 mm
Selective fit adjuster plates ........ 0.5 and 0.8 mm
IGNITION SYSTEM
The ignition system is an integral part of the
engine management system. The Specifications, testing
and overhaul procedures are fully covered in the Fuel
and Engine Management section.

TORQUE WRENCH SETTINGS
Alternator pulley retaining nut:
Bosch ......................................................... 50 Nm
Hitachi ....................................................... 59 Nm
1. BATTERY AND CHARGING SYSTEM
TROUBLE SHOOTING

BATTERY UNDERCHARGED
3. Loose or broken drive belt: Adjust or renew
the drive belt. 4. Faulty alternator regulator; Renew the regu-
lator unit.
5. Faulty battery: Install a new battery of
the
recommended type and capacity. 6. Faulty alternator: Overhaul or renew the
alternator. 7. Fault in the charging circuit wiring: Check
and repair or renew the wiring harness. 8. Faulty connections in the charging circuit:
Check and repair the connections. 9. Fusible link blown; Rectify the fault and
renew as necessary.
NOTE: Check the state of charge (specific
gravity) of the battery- as described under
the
Battery heading in this section. If the battery
is undercharged, check the possible causes in
the order given.

BATTERY OVERCHARGED
• Faulty alternator regulator unit:
Renew the
regulator unit.
• Faulty alternator: Overhaul or
renew the
alternator. • Faulty charging circuit wiring or
connec-
tions: Check and renew or repair the faulty
compo-
nents.
NOTE: An overcharged battery is indicated
by continual loss of water through boiling.

Electrical System 201
nosed pliers. This will safeguard the diodes
by transferring any excess heat to the jaws of
the pliers.

Using a suitable drift, install the bearing into
the drive end bracket, install the retainer plate and
screws. Tighten the screws securely. Using a suitable press and press plates, install
the bearing to the slip ring end of the rotor shaft.
Ensure that pressure is ex erted only on the inner race
and that the stop ring groove is nearest to the sl i p
rings. Ensure that the rotor sh aft rear bearing stop
ring is positioned so that the protruding part of the
ring is located in the deepest part of the groove. Install the stator, diode pack and
regulator
assembly to the slip ring e nd bracket. Install the
retaining nuts and washers and tighten securely. Install the nut and insulator to the terminal
and tighten securely. Using a piece of wire, hold the brushes in a
retracted position. Hold the drive end bracket in a soft jawed
vice and install the rotor shaft assembly to the drive
end bracket. Install the pulley, retaining nut and washer to
the rotor shaft and tighten the retaining nut to the
specified torque. Apply a heated 200 watt soldering iron to the
slip ring end bracket at the bearing mounting boss for
3-4 minutes to heat the bracket and allow the
installation of the rotor shaft rear bearing. Aligning the marks made on dismantling and
ensuring that the rotor sh aft rear bearing retaining
ring protrusion is located in the deepest part of its
groove, install the rotor/stator assembly to the slip ring
end bracket.
Remove the brush retr acting wire from the
alternator, ensure that the alternator component
marks are aligned, install the retaining through bolts
and tighten them securely. Check the alternator rotor for smooth oper-
ation and install the al ternator to the vehicle
as
previously described.
Check the alternator operation on the vehicle
as previously described.
8. STARTER MOTOR
Special Equipment Required:
To Renew Brushes — Soldering iron
To Renew Armature Bearings — Bearing puller
DESCRIPTION
Two types of starter motors are installed to the
range of vehicles covere d by this manual, either
Hitachi or Bosch.

The starter motor is the induced pole type with
four brushes and four pole shoes with field coils.

A solenoid switch is attached to the starter drive
end bracket. The solenoid plunger is connected to
the overrunning clutch and drive pinion assembly
through a lever and pivot arrangement.

When the solenoid windings are energized, the
plunger acting on the lever and pivot engages the drive
pinion with the flywheel ri ng gear and at the same
time closes the switch supplying power from the
positive lead of the battery to the starter motor field
coils and armature to operate the motor.

As the engine fires, the over-running clutch of the
drive pinion assembly prevents high speed rotation of.
and possible damage to, the starter armature if the
solenoid windings are not immediately de-energized
by releasing the ignition key.

The starter solenoid switch windings are energized
by the ignition switch.

TO TEST ON VEHICLE
Should the starter motor fail to operate when the
ignition switch is turned to the Start position, check
the following points:

Check the battery condition and state of
charge. Refer to the Battery heading for the correct
procedure.
Clean the battery terminals, taking particular
care to remove the scale from the positive ( + )
terminal post and terminal. Check the earth connection for tightness and
cleanliness.
Switch on the headlamps and turn the igni-
tion switch to Start. If the lamps dim but the starter
motor does not operate, it could indicate that a short
circuit has developed in the starting system. Check that the engine is not seized or that the
starter motor drive pinion and ring gear are not
locked as these conditions would -give the same
indications as above.

(5) If the lamps do not dim and the starter
motor does not operate, this would indicate an open
circuit such as a broken or disconnected wire or a
switch not operating.

If the vehicle is equipped with an automatic
transaxle, turn the ignition switch to Start and move
the selector lever through all the gear selection range.
If the starter motor operates in any position other
than N or P, the neutral safety switch is faulty.

(6) Check all the external wiring to ensure that
the fault is not external. If the external circuit proves
satisfactory, indicating that the problem is in the
starter motor, the unit will have to be removed and
tested.

TO REMOVE AND INSTAL
Disconnect the negative battery terminal.
Disconnect the wiring from the starter motor
solenoid. Remove the starter motor mounting bolts,

202 Electrical System


View of the Bosch starter motor removed from the
vehicle.
noting the position of the earth cable, and maneuver
the starter motor out of the engine compartment.

Installation is a reversal of the removal procedure
with attention to the following points:

Replace the earth cable to the position noted
on removal.
Tighten the starter motor mounting bolts
securely.
HITACHI STARTER MOTOR

To Dismantle
Remove the starter motor from the vehicle
as previously described. Mount the starter motor upright in a soft
jawed vice gripping the drive end bracket. Loosen the solenoid field coil terminal nut
and disconnect the cable from the solenoid.
Scribe a line across the drive end bracket,
yoke and end cover to facilitate correct alignment
during assembly. Remove the bolts retaining the end cover
and yoke to the drive end bracket and remove the end
cover from the yoke. Remove the yoke, armature and brush
holder as an assembly from the drive end bracket.
Note the position of the O ring sealing the yoke. Release the brush spri ngs and separate the
brushes from the brush holder. Remove the brush holder from the yoke.
Separate the armature from the yoke.
Scribe a line across the solenoid and the
drive end bracket to facilitate correct alignment
during assembly. Remove the solenoid retaining bolts and lift
the solenoid, spring, lever an d rubber seal out of the
drive end bracket. Note the installed position of the
components. Mount the drive end bracket in the vice with
the pinion uppermost and Remove the screws retaining
the pinion housing to the drive end bracket. Remove the pinion housing from the drive
end bracket,
Remove the pinion assembly from the drive
end bracket, Mount the pinion in the vice, hold the collar
down and remove the snap ring from the end of the
pinion. Remove the collar and spring from the
pinion and slide the pinion out of the clutch assembly. If necessary, prise the bearings off the clutch
assembly using two screwdri vers. Note the location of
the larger bearing. If necessary, remove the bearings from the
armature using a bearing puller.
To Check and Inspect

Clean all the starter motor components thor-
oughly but do not immerse the yoke, armature or
clutch assembly in cleaning solvent.
Check the brush holder insulation using an
ohmmeter. Connect one test probe to the brush holder
positive side and the other test probe to the negative
side. If continuity exists , renew the brush holder.

Check the brushes for adequate length. Re-
new the brushes if they are worn to less than the
length listed in Specifications. The brushes should be
a free sliding fit in the brush holders. Check the brush
springs for adequate tension.
Check the field coil continuity using an
ohmmeter. Connect one test probe to the positive
brush and the other test probe to the solenoid cable
terminal. If continuity does not exist, renew the field
coils.
View of the Hitachi starter motor removed from the
vehicle
.

Electrical System 203
BRUSH HOLDER
Dismantled view of the Hitachi starter motor.
Check the field coil insulation using an
ohmmeter. Connect one test probe to the solenoid
cable terminal and the other test probe to the body of
the yoke. If continuity exists, renew the field coils. Check that the commutator is free from
pitting and burning. Clean the commutator with a
petrol moistened cloth and polish with a strip of fine
glass paper.
A badly worn commutator may be repaired by
mounting in a lathe and taking a light cut using a very
sharp tool with the lathe rotating at high speed. After
machining, undercut the insulation between the seg-
ments to Specifications. Do not machine the commu-
tator to below 29 mm diameter. Check the armature
gear teeth for wear and damage.

Check the armature for short circuit using an
ohmmeter. Place one of the test probes on the
armature shaft or core and move the other test probe
around the periphery of the commutator. If continuity
exists at any point, the armature is faulty and should
be renewed. Check the pinion for wear and damage. The
pinion should move smoothl y along the clutch assem-
bly helical splines. Check the spring, collar and snap
ring for serviceability.
Check that the clutch assembly locks in one
direction and rotates smoothly in the opposite direc-
tion. Check for wear and damage to the reduction gear
teeth on the outside of the clutch assembly.
Check that continuity exists between the
solenoid spade terminal and the solenoid body and
between the solenoid spade terminal and the solenoid
field coil terminal. Renew the solenoid if continuity
does not exist. Renew all the components found to be
unserviceable in the above checks.
To Assemble

Assembly is a reversal of the dismantling proce-
dure with attention to the following points:

(1) If removed, install new bearings to the clutch
assembly and the armature. Lubricate the armature
bearings with high temperature grease.

The sealed bearings on the clutch assembly are
lubricated during manufacture and further lubrication
is unnecessary.

Apply high temperature grease to the yoke
end cover bearing recess, the drive end bracket and
pinion housing bearing recesses, the clutch assembly
reduction gear teeth, the armature gear teeth, the
pinion helical splines, th e solenoid plunger and the
spring and lever. Install the pinion to the clutch assembly and
install the spring and collar to the pinion. Hold the collar down and install the snap ring
to the end of the pinion.
Position the collar over the snap ring. If
necessary, squeeze the snap ring into the groove using
multigrip pliers to enable the collar to be clipped over
the snap ring. Install the pinion and clutch assembly to the
drive end bracket.
Install the pinion housing to the drive end
bracket. Install and tighten the retaining screws
se-
curely. Check that the pinion rotates freely.
Assemble the lever and spring to the solenoid
in the position noted on dismantling.
Install the solenoid assembly and rubber seal
to the drive end bracket.
Install and tighten the solenoid retaining
bolts securely. Connect 12 volts between the solenoid spade
terminal and the solenoid field coil terminal and
measure the distance that the end of the pinion
protrudes from the pinion housing. Pull the pinion by hand until it contacts the stop
and measure the pinion end protrusion.

If necessary, add or subt ract shims between the
solenoid mounting face and the drive end bracket
until the difference between the above measurements
is 0.3-1.5 mm.

Install the armature to the yoke.
Install the brush holder to the yoke. Install
the
PLUNGER
O RING

Electrical System 205


Dismantled view of the brush holder assembly. Bosch
starter motor.
side and the other lead to the negative side. If there is
any indication of leakage the ohmmeter will show a
reading other than infinity. Repair or renew the brush
holder if leakage is evident.

(2) Check the brushes for adequate length.
Brushes should be renewed when their length is below
Specifications. They should be a free sliding fit in the
brush holders.

NOTE: Due to the difficulty involved in
removing and installing the brushes in the
Bosch starter motor, it is recommended that
the brush holder be renewed as an assembly.

(3) Check that the commutator is free from
pitting and burning. Clean with a petrol moistened
cloth and polish with a strip of fine glass paper.

A badly worn commutator may be repaired by
mounting in a lathe, spi nning at high speed, and
taking a light cut with a very sharp tool. After turning,
undercut the insulation between the segments.

(4) Check the armature for short circuit using an
ohmmeter.

Place one of the test lead s on the armature shaft
or core and move the other lead around the circum-
ference of the commutator. If the ohmmeter shows a
reading at any point the armature is faulty and should
be renewed.

Check the drive assembly clutch pinion teeth
for wear, scoring or chipping. A clutch in good
condition should take up the drive in one direction
only. It should rotate easily and smoothly in the
non-drive direction and the assembly should move
smoothly along the armature or drive shaft helical
splines.
Check the armature shaft bushes for wear
and renew as necessary. The old bushes must be
removed and the new ones pressed into the end
brackets using a polished mandrel of the exact diam-
eter of the armature shaft. NOTE: The new bushes must not be reamed
to size, as reaming will impair the porosity
of the bushes and cause early failure. New
bushes should be allowed to stand immersed
in clean light engine oil for one hour before
installation.

To Assemble
Assembly is a reversal of the dismantling proce-
dure with attention to the following points:

Lubricate the helix of the drive shaft lightly
with graphite grease and install the drive assembly
to
the drive shaft. Install the stop collar and snap ring, slide the
stop collar over the snap ring to lock the snap ring in
position.
Lubricate the bushes in both end brackets
sparingly with engine oil. Install the engaging lever and gear set into the
drive end bracket. Install the centre rear bracket and the engag-
ing lever seal into the drive end bracket.
Slide the brush holder assembly into position
on the commutator ensuring that the brush holders
are correctly positioned in the anchor points. Install the commutator end bracket to
the
armature, install the shims and C clip. Check that the armature end float is satisfac-
tory and adjust as necessary using shims of the correct
thickness.
Align the slot in the commutator end bracket
with the cut out on the wiring seal and install the
armature end cover to the commutator end bracket.
Install the cover retaini ng screws but do not tighten.
Ensure that the permanent magnets in the
yoke have not picked up any debris and slide the yoke
over the armature ensuring that the wiring seal locates
correctly in the slot in the yoke.

View showing the planetary gear set. Bosch starter
motor.